U.S. patent application number 10/365255 was filed with the patent office on 2003-08-21 for balloon catheter for delivering therapeutic agents.
Invention is credited to Kokish, Lyudmila.
Application Number | 20030158517 10/365255 |
Document ID | / |
Family ID | 25038906 |
Filed Date | 2003-08-21 |
United States Patent
Application |
20030158517 |
Kind Code |
A1 |
Kokish, Lyudmila |
August 21, 2003 |
Balloon catheter for delivering therapeutic agents
Abstract
A drug delivery device for delivering therapeutic agents and
method of making such a device. The device including an inflatable
balloon having a plurality of holes formed in the wall of the
balloon. A microporous coating covers a portion of the outer
surface of the wall of the balloon. The thickness of the coating
and the size of the micropores can permit controlled delivery of a
substance from the micropores of the coating and into the tissue of
a patient's lumen.
Inventors: |
Kokish, Lyudmila; (Los
Gatos, CA) |
Correspondence
Address: |
Paul J. Meyer, Jr.
Squire, Sanders & Dempsey L.L.P.
Suite 300
One Maritime Plaza
San Francisco
CA
94111
US
|
Family ID: |
25038906 |
Appl. No.: |
10/365255 |
Filed: |
February 11, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10365255 |
Feb 11, 2003 |
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09755386 |
Jan 5, 2001 |
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6544223 |
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Current U.S.
Class: |
604/103.01 |
Current CPC
Class: |
A61M 2025/105 20130101;
A61L 29/085 20130101; A61M 25/10 20130101; A61L 29/16 20130101;
A61L 29/146 20130101; A61M 2025/1086 20130101; A61L 2300/606
20130101 |
Class at
Publication: |
604/103.01 |
International
Class: |
A61M 029/00 |
Claims
What is claimed is:
1. A drug delivery device, comprising: an elongated shaft having a
distal end and a proximal end; and an inflation assembly coupled to
said distal end of said elongated shaft, said inflation assembly
including an inflatable balloon having a plurality of holes defined
in a wall of said balloon; and a microporous coating covering an
outer surface of said balloon wall, said microporous coating having
a plurality of micropores of a size that permits controlled
delivery of a substance from the elongated shaft to said holes in
said balloon and through said micropores of said coating covering
said balloon.
2. The device of claim 1, wherein said holes are laser drilled with
a diameter in a range from approximately 0.01 mm to 0.1 mm
(3.94.times.1 inch to 3.94.times.10.sup.-3 inch).
3. The device of claim 1, wherein said size of said micropores is
in a range from approximately 0.001 mm (3.94.times.10.sup.-5 inch)
to 0.020 mm (7.87.times.10.sup.-4 inch).
4. The device of claim 1, wherein a thickness of said microporous
coating is in a range from approximately 0.005 mm
(1/97.times.10.sup.-4 inch) to 0.020 mm (7.87.times.10.sup.-4
inch).
5. The device of claim 1, wherein said microporous coating is made
using phase inversion precipitation techniques.
6. The device of claim 1, wherein said microporous coating is
formed from a polymer, a solvent and non-solvent.
7. The device of claim 6, wherein said polymer is taken from the
group consisting of: silicones, polyesters and polyurethanes.
8. The device of claim 6, wherein said solvent is taken from the
group consisting of: tetrahydro-furan (THF), dimethylacetamide,
dimethylformamide, dimethylsuylfoxide and dioxane.
9. The device of claim 6, wherein said non-solvent is water.
10. The device of claim 1, wherein said drug is taken from the
group consisting of: antithrombotics, antiproliferatives,
anti-inflammatory agents, smooth muscle cell migration inhibitors,
reendothelialization agents and restenosis-reducing drugs.
11. A method for making a drug delivery device comprising:
providing a catheter-based device having a porous inflatable member
secured at a distal end of said device; coating said porous
inflatable member with a first and a second solution; and drying
said coating to produce a precipitate on said porous inflatable
member.
12. The method of claim 11, further comprising after providing a
catheter-based device the act of: partially inflating said porous
inflatable member with a fluid.
13. The method of claim 12, further comprising before partially
inflating said porous inflatable member the act of: rotating said
porous inflatable portion about an axis of said porous inflatable
portion.
14. The method of claim 12, wherein said inflating is performed at
a variable pressure within the range of approximately 1 psi to 2
psi.
15. The method of claim 11, wherein said precipitate forms a
microporous coating.
16. The method of claim 11, wherein said act of applying a first
solution and a second solution includes simultaneously spraying
said first solution and said second solution.
17. The method of claim 16, wherein said spraying of said first
solution and said second solution is at a same volumetric flux.
18. The method of claim 17, wherein said volumetric flux is
approximately within the range of 1-5 ml/min.
19. The method of claim 11, wherein said act of applying a first
solution and a second solution includes dipping said porous
inflatable member into said first solution and said second
solution.
20. The method of claim 11, wherein said act of drying said coating
includes oven drying said coating for approximately 4 hours at
40.degree. C.
21. The method of claim 11, wherein said act of drying said coating
includes vacuum drying said coating for approximately 12 hours at
40.degree. C.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a device and method of
making a porous membrane. More specifically, this invention relates
to a microporous membrane that can be formed on the outer surface
of the inflatable member of a balloon catheter.
BACKGROUND OF THE INVENTION
[0002] A variety of surgical procedures and medical devices are
currently used to relieve intraluminal constrictions caused by
disease or tissue trauma. An example of one such procedure is
percutaneous transluminal coronary angioplasty (PTCA). PTCA is a
catheter-based technique whereby a balloon catheter is inserted
into a blocked or narrowed coronary lumen of the patient. Once the
balloon is positioned at the blocked lumen or target site, the
balloon is inflated causing dilation of the lumen. The balloon is
deflated and the catheter is then removed from the target site and
the patient's lumen thereby allowing blood to freely flow through
the unrestricted lumen.
[0003] Although PTCA and related procedures aid in alleviating
intraluminal constrictions, such constrictions or blockages reoccur
in many cases. The cause of these recurring obstructions, termed
restenosis, is due to the body responding to the surgical
procedure. Restenosis of the artery commonly develops over several
months after the procedure, which may require another angioplasty
procedure or a surgical by-pass operation. Proliferation and
migration of smooth muscle cells (SMC) from the media layer of the
lumen to the intima cause an excessive production of extra cellular
matrices (ECM), which is believed to be one of the leading
contributors to the development of restenosis. The extensive
thickening of tissues narrows the lumen of the blood vessel,
constricting or blocking the blood flow through the vessel.
[0004] Stents, synthetic vascular grafts or drug therapies, either
alone or in combination with the PTCA procedure, are often used to
reduce, or in some cases eliminate, the incidence of restenosis.
The term "drug(s)," as used herein, refers to all therapeutic
agents, diagnostic agents/reagents and other similar
chemical/biological agents, including combinations thereof, used to
treat and/or diagnose restenosis, thrombosis and related
conditions. Examples of various drugs or agents commonly used
include heparin, hirudin, antithrombogenic agents, steroids,
ibuprofen, antimicrobials, antibiotics, tissue plasma activators,
monoclonal antibodies, and antifibrosis agents.
[0005] Since the drugs are applied systemically to the patient,
they are absorbed not only by the tissues at the target site, but
by all areas of the body. As such, one drawback associated with the
systemic application of drugs is that areas of the body not needing
treatment are also affected. To provide more site-specific
treatment, balloon catheters are frequently used as a means of
delivering the drugs exclusively to the target site. The balloon
assembly of the balloon catheter is positioned at the target site
and inflated to compress the arteriosclerosis and dilate the walls
of the artery. The therapeutic agent is then administered directly
to the target site through small holes or apertures in the wall of
the balloon assembly. The apertures through the balloon may be
formed by mechanical punching, mechanical drilling, directing a
laser beam at the elastic material, directing an ion beam at the
elastic material, or directing an electron beam at the elastic
material, among other possibilities.
[0006] Apertures formed in the walls of the balloon assembly offer
many advantages to potential users. However, such devices may be
deficient in their drug delivery characteristics. For example, when
the balloon is filled with therapeutic or-diagnostic liquids/fluids
under relatively high pressure, fluid is ejected from the apertures
in the form of a jet-like flow. The fluid jetting from the
apertures is at such a velocity so as to cause tissue damage to the
lumen or vessel wall. Since the rate at which the drug is released
or delivered to the target site is a function of the structural
properties of the apertures, drug release rates are inadequately
controlled. As such, the balloon configuration greatly limits the
usefulness of the catheter.
SUMMARY OF THE INVENTION
[0007] In view of the above, it is apparent that there is a need to
provide a drug delivery device that delivers drugs, therapeutic
agents, diagnostic fluids and the like deep within the tissue
without causing damage to the tissue and significant systemic loss
of delivered fluid materials. It is also desirable that the
drug-delivery device allows one or more drugs to be released at
controlled rates. There is also a need to provide a method of
manufacturing such an improved drug delivery device that is
convenient, efficient and cost effective.
[0008] In one embodiment of the present invention, the drug
delivery device includes an elongated shaft, having a distal end
and a proximal end, and an inflation assembly coupled to the distal
end of the elongated shaft. The inflation assembly includes an
inflatable balloon having a plurality of holes formed in the wall
of the balloon. Further, a microporous coating covers a portion of
the outer surface of the wall of the balloon. The thickness of the
coating and the size of the micropores permit controlled delivery
of a substance from the elongated shaft to the holes in the balloon
and through the micropores of the coating covering the balloon.
[0009] Another aspect of the present invention is a method for
making a drug delivery device. In one aspect of the invention, the
method includes providing a catheter-based device having a porous
inflatable member secured at a distal end of said device. A first
solution and a second solution are applied onto the porous
inflatable member to coat the outer surface of the porous
inflatable member. The coating is then dried to produce a
microporous precipitate on the outer surface of the porous
inflatable member.
[0010] In general, drug(s) flow through the elongated shaft and
into the inflatable member causing the inflatable member to
inflate. Upon reaching a predetermined pressure, the drug(s) stream
out of the holes of the inflatable member and disseminate from the
pores of the microporous coating at a controlled release rate.
Generally, the flow rate of fluid from the coated inflatable member
is a function of the thickness and pore size of the microporous
coating. As such, the microporous coating disperses the jet-like
streams of liquid ejected from the holes of the inflatable member
so that the fluid oozes or controllably exudes from the microporous
coating to prevent the jetting effect from damaging tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The features of the described embodiments are specifically
set forth in the appended claims. However, embodiments relating to
both structure and method of operation are best understood by
referring to the following description and accompanying drawings,
in which similar parts are identified by like reference
numerals.
[0012] FIG. 1 is a sectional view of a drug delivery device in
accordance with an embodiment of the present invention;
[0013] FIG. 2 is a perspective view of the drug delivery device of
FIG. 1;
[0014] FIG. 3A illustrates an alternate perspective view of a drug
delivery device in accordance with an embodiment of the present
invention;
[0015] FIG. 3B is a sectional view of a portion of the drug
delivery device of FIG. 3a;
[0016] FIG. 3c is a sectional view of a drug delivery device
inserted in the lumen of a patient;
[0017] FIG. 4 illustrates a perspective view of an embodiment of
applying a coating to a drug delivery device in a partially
inflated configuration; and
[0018] FIG. 5 illustrates an alternate perspective view of the drug
delivery device in a deflated configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1 illustrates a drug delivery device 10. For
convenience and ease of comprehension, the medical device
referenced in the text and figures of the present disclosure is a
balloon catheter. However, it should be noted that other medical
devices or prosthesis including, but not limited to, stents, stent
coverings, vascular grafts, or other implantable devices, are also
within the scope of the claimed invention.
[0020] As shown in FIG. 1, the catheter 10 generally comprises an
elongated shaft 21 having a distal end 14 and a proximal end (not
shown). In one embodiment, the catheter shaft 12 houses an outer
tubular member 16, an inner tubular member 18, an annular lumen 20
extending between the inner and outer tubular members 18, 16 and an
inflation assembly 22 on the distal extremity of the catheter shaft
12. The inflation assembly 22 includes a porous inflatable member
or balloon 24 that is secured at its distal end 26 to the inner
tubular member 18 and is secured at its proximal end 28 to the
outer tubular member 16. Adhesives, welds, heat bonding or other
conventional attachment devices or methods not specifically
described herein can be used to secure the inflation assembly 22 to
the tubular members 18,16. For convenience and ease of
comprehension, the catheter 10 referenced in the text and figures
of the present disclosure is configured according to the
above-described design. However, it should be noted that other
catheter-based designs are also within the scope of the claimed
invention.
[0021] The structural dimensions and materials of construction for
the inner and outer tubular members 18,16 can be selected from
conventional materials and dimensions. Conventional methods of
making the tubular members 18,16 can also be employed. In one
embodiment, inner and outer tubular members 18,16 can be made from
extruded polyethylene. However, other materials can be used,
including, but not limited to, nylon, thermoplastic elastomer
resins (e.g., Pebax.RTM.), PEEK (polyetheretherketone), and
thermoplastic polyester elastomers (e.g., Hytrel.RTM.). The inner
tubular member 18 is approximately 137 cm (53.94 inches) in length
and has internal and external diameters of about
4.445.times.10.sup.-2 cm (0.0175 inch) and 5.715.times.10.sup.-2 cm
(0.0225 inch), respectively. The approximate length and internal
and external diameters of the outer tubular member 16 are 135 cm
(53.15 inches), 7.112.times.10.sup.-2 cm (0.028 inch), and 0.0864
cm (0.034 inch), respectively.
[0022] The inner tubular member 18 of the catheter 10 is configured
to slidably receive a guide wire 30. The guide wire 30 extends from
beyond the distal end 14 of the catheter 10 to a guide wire exit
(not shown) located near the proximal end of the catheter 10. The
guide wire 30 serves as the steering mechanism of the catheter 10
and enables an operator to maneuver the catheter 10 through the
various vessels and lumens of the patient to the chosen target
site. In one embodiment, overall length and diameter of the guide
wire 30 are within the range of approximately 190 cm to 300 cm
(74.8 inches to 118.1 inches) and 0.0386 cm to 0.0483 cm (0.0152
inch to 0.019 inch),respectively. The guide wire 30 maybe
fabricated from a variety of materials including, but not limited
to, stainless steel, Nitinol.TM., platinum and polymers. These and
other similar materials exhibit the required structural properties,
such as strength and flexibility, desired in guide wire
elements.
[0023] As shown in FIGS. 1 and 2, the inflation assembly 22
generally comprises a porous inflatable balloon 24. The inflatable
balloon 24 may be used for various procedures including, but not
limited to, opening narrowed passageways, distributing drugs to
specific target sites, and delivering/positioning stents or other
medical devices within the lumen. The term "target site," as used
herein, refers to sites or tissue areas both inside and outside the
lumen. During use, the inflatable balloon 24 is initially deployed
in a low profile, deflated condition. When the balloon 24 is
positioned at the target site, it is inflated with fluid via an
inflation port (not shown) located near the proximal end of the
catheter 10. During inflation of the balloon 24, fluid flows from
the inflation port, through the annular lumen 20, and to the
balloon 24. In addition, the fluid flows through the same lumen.
20, but in the opposite direction, upon deflation and subsequent
removal of the balloon 24.
[0024] The inflatable balloon 24 can be formed from any of several
polymers, such as polyolefin, polyester, nylons, polyurethanes and
fluoropolymers. These and other similar elastically expandable
materials may be used and are available from a variety of
manufacturers, examples of which include Polyester Carodel 5922C
(Melinar). In one embodiment, the thickness of the wall 32 of the
inflatable balloon 24 is approximately 0.00127 cm (0.0005 inch)
thick. However, the wall 32 of the balloon 24 can be of any
appropriate thickness provided that the thickness does not
compromise properties that are important for achieving optimum
performance. Such properties include high burst strength, good
flexibility, high resistance to fatigue, ability to fold, ability
to cross and re-cross a desired treatment area or occluded region
in a body lumen, and low susceptibility to defects caused by
handling, among other properties not specifically mentioned herein.
As such, balloon wall thickness can be within the range of
approximately 0.00127 cm (0.0005 inch) to 0.3048.times.10.sup.-2 cm
(0.0012 inch) thick.
[0025] A plurality of pores or holes 34 is formed in the wall 32 of
the inflatable balloon 24 and extends from the inner surface 35
through to the outer surface 36 of the wall 32. The holes 34 can be
formed by laser drilling, mechanical punching, mechanical drilling,
ion-bean drilling, electron beam drilling techniques or other
conventional methods well known in the art. In general, the holes
34 are configured into a variety of shapes including, but not
limited to, oval, circular and elliptical. As shown in FIGS. 3A and
3B, the size or diameter X of each hole 34 is approximately 0.01 mm
to 0.1 mm (3.94.times.10.sup.-4 inch to 3.94.times.10.sup.-3 inch)
when the balloon 24 is in a inflated condition. The quantity, size
and shape of the holes 34 can be varied, depending on the desired
application or treatment.
[0026] The outer surface 36 of the inflatable balloon 24 is coated
with one or more layers of a microporous coating or membrane 38
having a plurality of micropores 40 throughout the coating layer
38. The size or diameter Y of the pores 40 of the coating 38 ranges
from approximately 0.001 mm (3.94.times.10.sup.-5 inch) to 0.020 mm
(7.87.times.10.sup.-4 inch). The thickness T of the coating 38 is
also variable from approximately 0.005 mm (1/97.times.10.sup.-4
inch) to 0.020 mm (7.87.times.10.sup.-4 inch). The holes 34 in the
wall 32 of the inflatable balloon 24, together with the microporous
coating 38 covering the outer surface 36 of the balloon 24, permit
delivery of drugs radially outward from the balloon 24 and into the
wall of the patient's lumen in a controlled manner.
[0027] As shown in FIG. 3c, when the device is positioned at the
target site 42, the surface 44 of the microporous coating 38
engages the wall 46 of the patient's lumen 48. In general, drug(s)
flow through the catheter shaft 12 and into the balloon 24 causing
the balloon 24 to inflate. Upon reaching a predetermined pressure,
the drug(s) stream out of the holes 34 of the balloon 24.
Microporous coating 38 disperses the jet-like streams of liquid
ejected from the holes 34 of the inflatable balloon 24 into coating
38 before the streams of liquid can contact the target site. Under
the pressure of the dispersed streams of liquid, and because of the
numerous pores 40, the liquid can ooze or controllably exude from
microporous coating 38 and disseminates from the pores 40 at a
controlled release rate. Generally, the flow rate of fluid from the
coated balloon is a function of the thickness and pore size of
microporous coating 38.
[0028] The terms "drug(s)," "fluid(s)," or "liquid(s)," as used
herein, refers to a variety of drug classes and therapeutic
substances may be used in accordance with the present disclosure.
For example, therapeutic substances or agents may include, but are
not limited to, antineoplastic, antimitotic, anti-inflammatory,
antiplatelet, anticoagulant, antifibrin, antithrombin,
antiproliferative, antibiotic, antioxidant, and antiallergic
substances as well as combinations thereof. Examples of such
antineoplastics and/or antimitotics include paclitaxel (e.g.
TAXOL.RTM. by Bristol-Myers Squibb Co., Stamford, Conn.), docetaxel
(e.g. Taxotere.RTM., from Aventis S. A., Frankfurt, Germany)
methotrexate, azathioprine, vincristine, vinblastine, fluorouracil,
actinomycin-D, doxorubicin hydrochloride (e.g. Adramycin.RTM. from
Pharmacia & Upjohn, Peapack N.J.), and mitomycin (e.g.
Mutamycin.RTM. from Bristol-Myers Squibb Co., Stamford, Conn.)
Examples of such antiplatelets, anticoagulants, antifibrin, and
antithrombins include sodium heparin, low molecular weight
heparins, heparinoids, hirudin, argatroban, forskolin, vapiprost,
prostacyclin and prostacyclin analogues, dextran,
D-phe-pro-arg-chloromethylketone (synthetic antithrombin),
dipyridamole, glycoprotein IIb/IIIa platelet membrane receptor
antagonist antibody, recombinant hirudin, and thrombin inhibitors
such as Angiomax TM (Biogen, Inc., Cambridge, Mass.) Examples of
such cytostatic or antiproliferative agents include angiopeptin,
angiotensin converting enzyme inhibitors such as captopril (e.g.
Capoten.RTM. and Capozide.RTM. from Bristol-Myers Squibb Co.,
Stamford, Conn.), cilazapril or lisinopril (e.g. Prinivil.RTM. and
Prinzide.RTM. from Merck & Co., Inc., Whitehouse Station,
N.J.); calcium channel blockers (such as nifedipine), colchicine,
fibroblast growth factor (FGF) antagonists, fish oil (omega 3-fatty
acid), histamine antagonists, lovastatin (an inhibitor of HMG-CoA
reductase, a cholesterol lowering drug, brand name Mevacor.RTM.
from Merck & Co., Inc., Whitehouse Station, N.J.), monoclonal
antibodies (such as those specific for Platelet-Derived Growth
Factor (PDGF) receptors), nitroprusside, phosphodiesterase
inhibitors, prostaglandin inhibitors, suramin, serotonin blockers,
steroids, thioprotease inhibitors, triazolopyrimidine (a PDGF
antagonist), and nitric oxide. An example of an antiallergic agent
is permirolast potassium. Other therapeutic substances or agents
which may be appropriate include alpha-interferon, genetically
engineered epithelial cells, and dexamethasone.
[0029] While the above listed substances or agents are well known
for preventative and therapeutic utility, the substances are listed
by way of example and are not meant to be limiting. Other
therapeutic substances which are currently available or that may be
developed in the future are equally applicable. The treatment of
patients using the above mentioned medicines is well-known to those
of ordinary skill in the art.
[0030] The microporous coating 38 formed on the outer surface 36 of
the inflatable balloon 24 can be made according to phase inversion
precipitation techniques using a variety of materials. For example,
silicones, polyesters or polyurethanes dissolved in
tetrahydro-furan (THF), dimethylacetamide, dimethylformamide,
dimethylsuylfoxide or dioxane, or other mixtures of solvents can be
used. Non-solvents, such as water, can also be used during
preparation of the unstable polymer coating solution.
[0031] Phase inversion precipitation techniques are well known in
the manufacture of microporous membranes. In general, according to
this technique, a solution of a polymer is prepared in a mixture of
two miscible solvents. One of the two solvents is a poorer solvent
for the polymer and less volatile than the other solvent. The
solution is selectively coated onto the device 10 according to one
of several coating methods, such as dipping, spraying, etc. Once
the device 10 is properly coated, the solution is allowed to air
dry at 40.degree. C. and dry over-night in a vacuum chamber. During
the drying phase of the solution, the better solvent evaporates
more rapidly than the poorer solvent, causing the polymer to form a
precipitant out of the solution. After the solution is completely
dried, an open porous structure (i.e. the precipitant) remains and
covers the selected areas of the device 10. The size of the
resultant pores is determined by the nature of the ingredients
(i.e. polymers, solvents, non-solvents) and relative concentrations
of the ingredients chosen.
[0032] Microporous Coating Techniques
[0033] To aid in the treatment of various conditions affecting a
body lumen, the outer surface 36 of the porous, inflatable balloon
24 of a catheter 10 is coated with a microporous membrane 38.
Various methods can be employed to coat the inflatable balloon 24.
The following examples illustrate various microporous coating
techniques, but do not limit possible techniques within the scope
of the present invention.
Example 1
[0034] The inflatable member 24 of a balloon catheter 10 having a
plurality of holes 34 formed in the wall 32 of the 30 mm by 20 mm
(1.18 inch by 0.79 inch) balloon 24 is suspended from a fixture
(not shown) and partially inflated. In one embodiment,
approximately 6.9 kPa-13.8 kPa (approximately 1-2 psi) of air flows
from the inflation port (not shown), through the annular lumen 20,
and into the inflatable balloon 24 causing the balloon 24 to
partially inflate. Other fluids, such as nitrogen, at variable
pressures, ranging from about 6.9 kPa-13.8 kPa (about 1 psi to 2
psi), can also be used to inflate the balloon 24. In general, the
desired fluid pressure flowing through the balloon should be an
amount that allows partial inflation of the balloon 24 while
maintaining the structural integrity of the microporous coating
38.
[0035] A first solution, i.e. polymer solution, is formulated using
1% w/w Tecoflex RTM EF-600 (Termedica, Inc.) dissolved in THF/1.4
Dioxane mixture (2:1). Note that "w/w" is an abbreviation for "by
weight," used in chemistry and pharmacology to describe the
concentration of a substance in a mixture or solution. For example,
25% w/w means that the mass of the substance is 25% of the total
mass of the solution or mixture. As shown in FIG. 4, the balloon
catheter 10 is rotated about its axis while maintaining the balloon
24 in its partially inflated configuration. The polymer solution
and a second solution, or non-solvent (i.e. water), are
simultaneously but separately sprayed from two spray guns 50
(Badger Airbrush #250-2) at about the same volumetric flux onto the
outer surface 36 of the rotating partially-inflated balloon 24. In
one embodiment, the polymer solution and non-solvent are sprayed at
a volumetric flux of between about 1-5.0 ml/min at nitrogen
pressure of about 103 kPa (15 psi). However, volumetric flux of the
polymer solution and non-solvent may vary based upon polymer type,
solvent characteristics, non-solvent characteristics, balloon size,
desired flow rate; desired coating thickness and pore size,
etc.
[0036] After the outer surface 36 of the balloon 24 is spray coated
with the mixture, the coating 38 (not shown) is allowed to air dry
for approximately 4 hours at 40.degree. C., with the balloon
partially inflated. The balloon catheter 10 is then transferred to
a vacuum drying oven for overnight drying (i.e. approximately 12
hours). After the coating 38 is completely dry, the above process
can be repeated until the desired coated balloon characteristics
are achieved.
Example 2
[0037] The inflatable member 24 of a balloon catheter 10 having a
plurality of holes 34 formed in the wall 32 of a 30 mm by 20 mm
(1.18 inch by 0.79 inch) balloon 24 is completely deflated to a
flattened configuration, as shown in FIG. 5. A first solution, i.e.
polymer solution, is formulated using 1% w/w Tecoflex RTM EF-600
(Ter medica, Inc.) dissolved in THF/1.4 Dioxane mixture (2:1). The
polymer solution and a second solution, or non-solvent such as
water, are carefully mixed to avoid precipitation during the mixing
process. In one embodiment, the concentration/ratio of polymer
solution to non-solvent is approximately 90:10. A coating or layer
of the mixture is then applied to the balloon 24 via dipping,
spraying or other appropriate application techniques. The total
volume of the mixture contained in each layer depends on the
desired balloon configuration. In one embodiment, a coating
thickness of 0.01 mm (3.94.times.inch) is applied to the 30 mm by
20 mm (1.18 inch by 0.79 inch) balloon 24.
[0038] After the outer surface 36 of the balloon 24 is coated with
the mixture, the coating 38 (not shown) is allowed to air dry for
approximately 4 hours at 40.degree. C. The balloon catheter 10 is
then further dried in a vacuum drying oven at about 40.degree. C.
for approximately 12 hours. After the coating 38 is completely dry,
the above process can be repeated until the desired coated balloon
characteristics are achieved.
[0039] The above-described coating examples are specific to
assembled balloon catheters 10. However, in an alternate
embodiment, the above described fabrication processes can also be
performed on the inflatable member 24 prior to its assembly on the
catheter shaft 12. In addition, alternative methods of applying a
microporous coating 38 onto the surface 36 of the inflatable member
24 of a balloon catheter 10, including various combinations of
methods, are also within the scope of the present disclosure.
Further, by modifying the ingredients (i.e. types and
concentrations of polymers, solvents and non-solvents), pores 40 of
varying sizes and quantities may be formed. For example, in one
embodiment, a single layer of coating 38 having smaller and more
numerous pores 40 may be preferred to control drug release
rates/duration. In an alternate embodiment, several layers of a
coating 38, whereby each layer is made of the same ingredients, may
be applied to achieve the desired fluid flow rate characteristics.
In yet another embodiment, each layer of coating 38 applied to the
balloon 24 is made of different ingredients, thereby providing
alternative fluid flow rate characteristics.
[0040] Although not specifically described, the scope of the
present invention also includes alternative coated balloon
embodiments having various combinations of ingredients and layering
patterns/methods. The particular coating ingredient(s) and layering
patterns applied to the balloon 24 are configured according to the
requirements of the desired treatment or diagnosis.
[0041] Although the invention has been described in terms of
particular embodiments and applications, one of ordinary skill in
the art, in light of this teaching, can generate additional
embodiments and modifications without departing from the scope of
the claimed invention. Accordingly, it is to be understood that the
drawings and descriptions herein are proffered by way of example to
facilitate comprehension of the invention and should not be
construed to limit the scope thereof.
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